November 17, 2010

Ion Digital Level Controller to Replace Mechanical Float Switches on Residential Sump and Sewage Pumps

Ion Digital Level Control Switch Product Release

The Ion Digital Level Control Switch is the first of its kind, solid state sensing technology. Completely replaces mechanical float switches, minimizing the most common cause for sump pump failures.

Metropolitan Industries is pleased to announce the launch of the Ion Digital Level Controller, designed and engineered for residential sump and sewage pumps. Under development for the last several years, the patent-pending digital level pump control switch eliminates moving parts, which are the detriment of most mechanical switches, and replaces it with solid-state sensing technology.

“The problem was never the pump because they are generally built to last,” says John Kochan, Jr., president of Metropolitan Industries. “The problem has always been the switch responsible for the critical task of turning the pump on and off.”

Kochan developed the idea for the new product by utilizing solid state components and applying them to switch technology.

“Mechanical switches use moving parts and wear and tear in a sump pit environment will always break those components down over time,” says Kochan, Jr.

While mechanical switches are useful and function properly over a period of time, they are always subject to failure. Switch failures translate into non-running pumps, which can result in flooded commercial, industrial and residential locations.

With the demand for reliable switches evident with recent recalls put forth by some of the largest pump manufacturers during the last decade, Metropolitan began work over a period of three years to develop a product that can outperform mechanical switches in longevity and dependability.

Ion Digital Level Controller Design and Engineering

The Ion Digital Level Controller is precisely designed and engineered to electronically activate and de-activate pumps, eliminating the all too frequent mechanical failures that happen with standard float switches.

How the Digital Level Sump Pump Controller Works

The Ion Digital Level Controller is a technologically advanced device that senses water level/pressure through the use of a proprietary sensor and microprocessor driven digital control. The microprocessor within the digital float sensor samples analog data from proprietary sensor, which electro-mechanically converts the water pressure to an electrical resistance. Because water pressure is directly proportional to the water height, the electrical resistance of the proprietary sensor is also proportional to the water height. The resistance of the proprietary sensor is measured by means of a resistive bridge network before passing into the microprocessors analog to digital converter.

Traditionally, sump and sewage pumps often have been started by means of a mechanical switch. The mechanical switch design often uses a set of electrical contacts which close under a given water height scenario, thereby activating the sump pump. Due to the alternating nature of the electrical voltage source from the utility, large voltage differentials could possibly be present across the mechanical switch contacts prior to turning on a pump. When a pump is suddenly turned on under these conditions, large transient current surges could be expected as the motor begins to rotate. These transient surges often cause heating of the electrical contacts which, over time, effectively reduce the lifetime of the switch. This condition is further amplified when a mechanical switch attempts to open and turn off the pump.

When a mechanical switch suddenly opens an inductive motor load, the time rate of change of the current flow can be very large. This value, multiplied by the motors internal inductance, induces a large voltage transient across the mechanical switch contacts. This transient often causes arcing of the contacts which, over time, can cause the switch to wear and ultimately fail. It is well known in the sump pump industry that the cause of most pumping failures occurs when the pumps switch fails.

The embodiments of the ION Switch effectively eliminate the problem of switching transients and contact arcing by incorporating both a solid state switching device in parallel with an electrical relay. When a pump is called for, the turn on cycle begins by enabling the solid state device, or triac. The nature of the triac in our design is to switch on a load under low voltage conditions. By starting the pump motor from a low voltage potential, both radiated and conducted electrical noise have been dramatically reduced.

The Ion Digital Level Control is universal and can be used in almost any pumping application dependent of level control as well as effluent sump and sewage. To customize operation, the Ion Digital Level Control has standard differential heights of 6 inches for standard sump applications and 10 inches for sewage applications and is inverter rated for use with most battery back up systems. The Ion can be programmed for custom applications as well.

A Digital Upgrade Alternative from Mechanical Float Switches

“We feel the Ion Digital Level Controller will transform the plumbing industry much the way battery back up systems did in the 1980s because we figured the way to eliminate the moving parts associated with most switch failures,” says Kochan, Jr.

“As wholesalers and plumbers realize there is a product available that can eliminate the problems associated with mechanical switches, it will only be a matter of time until mechanical switches are replaced entirely,” he added.


Among the key features of the Ion Digital Level Controller includes:

  • Contact protection specifically designed to handle high inrush current pump loads
  • First of a kind solid-state sensing technology
  • Leak resistant and extremely durable proprietary enclosure
  • Solid-state design with no contact points
  • Differential heights of 6-inch for standard sump applications and 10-inch for sewage applications
  • Multiple stainless steel screws supply optimized pressure ensuring superior sealing properties and durability

Additional specifications:

  • Rated for both effluent and sewage use with pumps using a piggy back plug system
  • Auto power reset, “no touch” design
  • No maintenance or cleaning required
  • Inverted rated for use with most back-up systems, including the AC-powered Ion Technologies line of backup systems
  • For use with all 120 vap pumps up to 15 amps
  • Factory calibrated
Metropolitan Industries, Inc. President John Kochan Jr with Ion Digital Level Control Switch

Metropolitan Industries Presdient John Kochan, Jr., holds the Ion® Digital Level Controller Switch.

Interested in Learning More?

The Ion Digital Level Control Switch was the catalyst that eventually led to the branding of Ion Technologies, our residential pumps division.

For more information, please continue to the Ion Technologies website.

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